1. Manuals
  2. Brands
  3. Hammerhead Manuals
  4. Industrial Equipment
  5. 100XT
  6. Operator's manual

Hammerhead 100XT Operator's Manual

Hide thumbs
Table of Contents

Advertisement

Quick Links

Download this manual
T E C H N I C A L P U B L I C AT I O N S
Operator's
Manual
100XT
Issue 3.0
960-1010
Original Instruction

Advertisement

Table of Contents
loading

Related Manuals for Hammerhead 100XT

Summary of Contents for Hammerhead 100XT

  • Page 1 T E C H N I C A L P U B L I C AT I O N S Operator's Manual 100XT Issue 3.0 960-1010 Original Instruction...

  • Page 2: Table Of Contents

    100XT Operator’s Manual Overview Chapter Contents Serial Number Location ..... . 2 Intended Use ....... 3 Equipment Modification .

  • Page 3: Serial Number Location

    100XT Operator’s Manual Serial Number Location Serial Number Location Record serial numbers and date of purchase in spaces provided. Date of manufacture Date of purchase 2 - Overview...

  • Page 4: Intended Use

    4” (10.2 cm) to 16” (40.6 cm) diameter buried pipes and conduits. The 100XT produces 100 tons (91 t) of pullback force. A power unit provides hydraulic power to run the pipe bursting unit.

  • Page 5: Unit Components

    100XT Operator’s Manual Unit Components Unit Components 1. Remote 3. Extraction cage 2. Rod box 4. Bursting unit 4 - Overview...

  • Page 6: Bursting Unit Components

    100XT Operator’s Manual Bursting Unit Components Bursting Unit Components j51om032w.eps 1. Bungee 3. Clamp 2. Carriage 4. Spinner Overview - 5...

  • Page 7: Operator Orientation

    100XT Operator’s Manual Operator Orientation Operator Orientation IMPORTANT: Top view of unit is shown. 1. Front of unit 2. Right side of unit 3. Rear of unit 4. Left side of unit Operating Area IMPORTANT: Top view of unit is shown.

  • Page 8: About This Manual

    100XT Operator’s Manual About This Manual About This Manual This manual contains information for the proper use of this machine. See Operation Overview for basic operating procedures. Cross references such as “See page 50” will direct you to detailed procedures.
  • Page 9 100XT Operator’s Manual About This Manual 8 - Overview...

  • Page 10: Foreword

    If you sell your equipment, be sure to give this manual to the new owner. If you need a replacement copy, contact your HammerHead dealer. If you need assistance in locating a dealer, visit our website at www.hammerheadtrenchless.com or write to the following address: HammerHead Trenchless Equipment 500 South C.P.
  • Page 11 Part number 960-1010 Copyright 2015, 2016, 2017, 2019 by Earth Tool Company LLC HammerHead and HydroBurst are registered trademarks of Earth Tool Company LLC. ® This product and its use may be covered by one or more patents at http://patents.charlesmachine.works.
  • Page 12 100XT Operator’s Manual Contents Overview machine serial number, information about the type of work this machine is designed to perform, basic machine components, and how to use this manual Foreword part number, revision level, and publication date of this manual, and factory contact...
  • Page 13 100XT Operator’s Manual Service Record a record of major service performed on the machine 12 - Contents...

  • Page 14: Safety

    100XT Operator’s Manual Safety Chapter Contents Guidelines ....... . 12 Emergency Procedures .

  • Page 15: Guidelines

    Use equipment carefully. Stop operation and investigate anything that does not look or feel right. • Do not operate unit where flammable gas may be present. • Only operate equipment in well-ventilated areas. • Contact your HammerHead dealer if you have any question about operation, maintenance, or equipment use 14 - Safety...

  • Page 16: Emergency Procedures

    100XT Operator’s Manual Emergency Procedures Emergency Procedures Jobsite hazards could cause death or serious injury. Use correct equipment and work methods. Use and maintain proper safety equipment. Before operating any equipment, review emergency procedures and check that all safety precautions have been taken.

  • Page 17: If An Electric Line Is Damaged

    100XT Operator’s Manual Emergency Procedures If an Electric Line Is Damaged If you suspect an electric line has been damaged and you are in pit, DO NOT MOVE and DO NOT TOUCH ANYTHING. Remain in pit and take the following actions. The order and degree of action will depend upon the situation.

  • Page 18: If A Gas Line Is Damaged

    100XT Operator’s Manual Emergency Procedures If a Gas Line is Damaged Fire or explosion possible. Fumes could ignite and cause burns. No smoking, no flame, no spark. Explosion possible. Serious injury or equipment damage could occur. Follow directions carefully. If you suspect a gas line has been damaged, take the following actions. The order and degree of action will depend on the situation.

  • Page 19: If A Fiber Optic Cable Is Damaged

    100XT Operator’s Manual Emergency Procedures If a Fiber Optic Cable is Damaged Do not look into cut ends of fiber optic or unidentified cable. Vision damage can occur. Contact utility company. If Machine Catches on Fire Perform emergency shutdown procedure and then take the following actions. The order and degree of action will depend on the situation.

  • Page 20: Safety Alert Classifications

    100XT Operator’s Manual Safety Alert Classifications Safety Alert Classifications These classifications and the icons defined on the following pages work together to alert you to situations which could be harmful to you, jobsite bystanders or your equipment. When you see these words and icons in the book or on the machine, carefully read and follow all instructions.

  • Page 21: Machine Safety Alerts

    100XT Operator’s Manual Machine Safety Alerts Machine Safety Alerts Lift point. See Transport chapter for more information. Tiedown location. See Transport chapter for more information. Moving parts could cut off hand. Stay away. 274-965 Misuse of machine can cause death or serious injury.
  • Page 22 100XT Operator’s Manual Machine Safety Alerts Hot parts may cause burns. Do not touch until cool or wear gloves. 275-355 (2-P), 273-423 (2-P) Flying objects thrown by machine may strike people. Wear safety glasses and hard hat. 275-193, 270-6903 Crushing weight could kill or seriously injure. Stay away.
  • Page 23 100XT Operator’s Manual Machine Safety Alerts 22 - Safety...

  • Page 24: Controls

    100XT Operator’s Manual Controls Chapter Contents Bursting Unit ......24 • Manual Controls ......... . .24 •...
  • Page 25 100XT Operator’s Manual Bursting Unit Bursting Unit Manual Controls IMPORTANT: Manual controls are used as a backup in the event the remote becomes inoperable. See “Setup and Configuration” on page 50. 1. Spinner clamp control 3. Clamp control 2. Spinner control 4.
  • Page 26 100XT Operator’s Manual Bursting Unit Item Description Notes 2. Spinner control Press up to rotate spinner counterclockwise (breakout). Pull down to rotate spinner clockwise (makeup). 3. Clamp control Press up to close clamp. Pull down to open clamp. 4. Push/Pullback control Press up to move carriage forward.
  • Page 27 100XT Operator’s Manual Bursting Unit Stabilizer Controls NOTICE: Raising one side of bursting unit too much can cause the unit to tip over. 1. Left stabilizer control 3. Rear stabilizer control 2. Right stabilizer control Item Description Notes 1. Left stabilizer control Pull back to raise.
  • Page 28 100XT Operator’s Manual Bursting Unit Item Description Notes 2. Right stabilizer control To raise, pull back. To lower, push forward. 3. Rear stabilizer control To raise, pull back. To lower, push forward. Controls - 27...
  • Page 29 100XT Operator’s Manual Bursting Unit Miscellaneous Controls Item Description Notes Auxiliary outlet Provides power for other Power output is fused to 15A equipment. 28 - Controls...
  • Page 30 100XT Operator’s Manual Remote Controller Remote Controller 1. Spinner control 6. Set pullback tons button 2. Remote stop button 7. Increase set tons button 3. Push/Pullback control 8. Decrease set tons button 4. Pullback force switch 9. Clamp control/Auto switch 5.
  • Page 31 100XT Operator’s Manual Remote Controller Item Description Notes 3. Push/Pullback control Press forward to move carriage forward. Center position neutral. Pull back to move carriage back. 4. Pullback force switch Press left to set pullback at IMPORTANT: Most jobs can be faster speed with less power completed with pullback set at 50.

  • Page 32: Prepare

    100XT Operator’s Manual Prepare Chapter Contents Gather Information ......32 • Review Job Plan ......... . .32 •...

  • Page 33: Gather Information

    100XT Operator’s Manual Gather Information Gather Information A successful job begins before the pull. The first step in planning is reviewing information already available about the job and jobsite. Review Job Plan Review blueprints or other plans and make sure you have taken enlargement during pullback into account.

  • Page 34: Inspect Site

    100XT Operator’s Manual Inspect Site Inspect Site Identify Hazards Entering a confined space without following all required procedures and having and effective emergency rescue plan can result in serious injury or death. To help avoid injury: • Follow local regulations for confined space.

  • Page 35: Select Installation And Bursting Pit Locations

    100XT Operator’s Manual Inspect Site Select Installation and Bursting Pit Locations Consider the following when selecting pit locations: Slope Consider how slope will affect unit setup and operation. Assess the risks on each slope to determine if factors affecting the risks create an unsafe condition for pipe bursting.

  • Page 36: Classify Jobsite

    100XT Operator’s Manual Classify Jobsite Classify Jobsite Jobsite hazards could cause death or serious injury. Use correct equipment and work methods. Use and maintain proper safety equipment. To help avoid injury: • Wear personal protective equipment including hard hat, safety eye wear, and hearing protection.

  • Page 37: Apply Precautions

    100XT Operator’s Manual Classify Jobsite Apply Precautions Once classified, precautions appropriate for jobsite must be taken. Follow U.S. Department of Labor regulations on excavating and trenching (Part 1926, Subpart P) and other similar regulations. Electric Jobsite Precautions Electric shock will cause death or serious injury. Stay away.
  • Page 38 100XT Operator’s Manual Plan Pull Path Crystalline Silica (Quartz) Dust Precautions Breathing crystalline silica dust may cause lung disease. Cutting, drilling, or working materials such as concrete, sand, or rock containing quartz may result in exposure to silica dust. Use dust control methods or appropriate breathing protection when exposed to silica dust.

  • Page 39: Prepare Jobsite

    100XT Operator’s Manual Prepare Jobsite Prepare Jobsite Jobsite hazards could cause death or serious injury. Use correct equipment and work methods. Use and maintain proper safety equipment. To help avoid injury: • If jobsite classification is in question or the possibility of unmarked electric utilities exists, classify jobsite as electric.

  • Page 40: Dig Installation And Bursting Pits

    100XT Operator’s Manual Prepare Jobsite Dig Bursting Pit Dimensions j51om030w.eps Minimum Bursting Pit Length (A) Width (B) Depth (C) U.S. (metric) U.S. (metric) U.S. (metric) 110” (2.8 m)* 48” (1.2 m) 18” (0.5 m)** *Add 73.5” (1.9 m) of length of bursting pit if using the extraction cage.
  • Page 41 100XT Operator’s Manual Prepare Jobsite Requirements Installation Pit (1) • Pit dimensions depend on pipe depth and product being installed. • Must be in line with existing pipe. • Sloped back end aids new product installation. Consider new product bend radius.

  • Page 42: Check Supplies And Prepare Equipment

    100XT Operator’s Manual Check Supplies and Prepare Equipment Check Supplies and Prepare Equipment Check Supplies • marking flags or paint • fuel • hydraulic oil • keys • cutting heads, clevis • barrier cones and tape • rod joint lube antiseize MIL-A-907E •...
  • Page 43 100XT Operator’s Manual Check Supplies and Prepare Equipment 42 - Prepare...

  • Page 44: Transport

    100XT Operator’s Manual Transport Chapter Contents Lift ........44 •...

  • Page 45: Lift

    100XT Operator’s Manual Lift Lift Crushing weight could cause death or serious injury. Stay away. Points Lifting points are identified by lifting decals. Lifting at other points is unsafe and can damage machinery. Procedure Bursting Unit Use equipment capable of supporting the unit's size and weight.
  • Page 46 100XT Operator’s Manual Lift Extraction Cage Use equipment capable of supporting the extraction cage's size and weight. See “Specifications” on page 83. Rod Box Use equipment capable of supporting the rod box's size and weight. j51om034w.eps Transport - 45...

  • Page 47: Tie Down

    100XT Operator’s Manual Tie Down Tie Down Points Tiedown points are identified by tiedown decals. Securing to trailer at other points can damage machinery. Procedure Bursting Unit To tie down bursting unit, use D-rings shown. NOTICE: Do not attempt to transport rod box with bursting unit.
  • Page 48 100XT Operator’s Manual Tie Down Rod Box To tie down rod box use D-rings shown. j51om035w.eps Transport - 47...
  • Page 49 100XT Operator’s Manual Tie Down 48 - Transport...

  • Page 50: Burst Pipe

    100XT Operator’s Manual Burst Pipe Chapter Contents Setup and Configuration ....50 Emergency Stop Procedure....53 Lock/Unlock Bungee .

  • Page 51: Setup And Configuration

    100XT Operator’s Manual Setup and Configuration Setup and Configuration j51om013w.eps 1. Bursting unit Hydraulic connection hoses Power unit Rod box Extraction cage Controller NOTICE: Follow U.S. Department of Labor regulations on excavating and trenching (Part 1926, Subpart P) and other similar regulations.
  • Page 52 100XT Operator’s Manual Setup and Configuration 1. Use equipment capable of safely lifting and unloading power unit, bursting unit, extraction cage, and related equipment next to bursting pit. 2. Set power unit switch to OFF. 3. Position power unit outside of bursting pit, at least two feet away from the edge.
  • Page 53 100XT Operator’s Manual Setup and Configuration Pressurized fluid or air could pierce skin and cause severe injury. Refer to operator’s manual for proper use. To help avoid injury: • Always connect return line first and remove last. • Before using system, check that all connections are tight and all lines are undamaged.

  • Page 54: Emergency Stop Procedure

    100XT Operator’s Manual Emergency Stop Procedure Emergency Stop Procedure To shut down power unit engine under normal conditions, use key switch or emergency stop on power unit. To shut down power unit using remote controller, press the remote stop switch on remote controller.

  • Page 55: Unlock Bungee

    100XT Operator’s Manual Lock/Unlock Bungee Unlock Bungee When bungee is unlocked, rod will move freely forward and backward. 1. Open clamp. 2. Move carriage to front of unit to compress bungee. 3. Remove bungee fork. 4. Move carriage to back of unit.

  • Page 56: Push Rods

    100XT Operator’s Manual Push Rods Push Rods Misuse of machine can cause death or serious injury. Read and understand operator’s manual and all other safety instructions before use. To help avoid injury: • Maintain 2-way communication between bursting pit and all other personnel.
  • Page 57 100XT Operator’s Manual Push Rods 9. Insert rod into bursting unit through open clamp until joint is visible in window (shown). 10. Close clamp. 11. Install rod. 12. To connect rods, rotate spinner clockwise. NOTICE: Tighten all threaded joints completely so shoulders touch.

  • Page 58: Connect Tooling String To Pilot Rod

    100XT Operator’s Manual Connect Tooling String to Pilot Rod Connect Tooling String to Pilot Rod Misuse of machine can cause death or serious injury. Read and understand operator’s manual and all other safety instructions before use. To help avoid injury: •...

  • Page 59: Pull Back Rods

    100XT Operator’s Manual Pull Back Rods Pull Back Rods Misuse of machine can cause death or serious injury. Read and understand operator’s manual and all other safety instructions before use. To help avoid injury: • Maintain 2-way communication between bursting pit and all other personnel.
  • Page 60 100XT Operator’s Manual Pull Back Rods 1. Place at least one operator/pipe loader in the bursting pit. Keep this person at rear of unit in operating area (page 6). 2. Start power unit engine. Set engine to high throttle. NOTICE: To shut down power unit when using remote controller, press the remote stop switch on remote controller.

  • Page 61: Pull New Product

    100XT Operator’s Manual Pull New Product Pull New Product Misuse of machine can cause death or serious injury. Read and understand operator’s manual and all other safety instructions before use. To help avoid injury: • Maintain 2-way communication between bursting pit and all other personnel.
  • Page 62 100XT Operator’s Manual Pull New Product 2. Continue pulling back rod string until bursting/splitting assembly reaches pit. 3. Connect one rod onto rod in bursting unit. 4. If not already in place, move bursting unit back in pit and position extraction cage between bursting unit and existing pipe and pit wall.
  • Page 63 100XT Operator’s Manual Pull New Product 62 - Burst Pipe...

  • Page 64: Systems And Equipment

    100XT Operator’s Manual Systems and Equipment Chapter Contents Tooling String ......64 •...

  • Page 65: Tooling String

    100XT Operator’s Manual Tooling String Tooling String Bursting String Ref. Description pipe pilot flex joint expander expander rod assembly pipe puller j51om006w.eps Slitter String Ref. Description flex joint slitter assembly trailing pivot rod assembly expander expander rod assembly pipe puller j51om007w.eps...

  • Page 66: Bursting/Splitting Heads

    100XT Operator’s Manual Extraction Cage Bursting/Splitting Heads Identification and Uses Ref. Type Uses slitter ductile iron, steel, cast iron with repairs pipe pilot clay, asbestos cement, PVC, PE, cast iron j51om008w.eps Extraction Cage The extraction cage allows room to remove the bursting/splitting assembly from the new product after it enters the bursting pit.
  • Page 67 100XT Operator’s Manual Extraction Cage 66 - Systems and Equipment...

  • Page 68: Complete The Job

    100XT Operator’s Manual Complete the Job Chapter Contents Disconnect Hoses......68 Stow Components ......69 Restore Jobsite .
  • Page 69 100XT Operator’s Manual Disconnect Hoses Disconnect Hoses Pressurized fluid or air could pierce skin and cause severe injury. Refer to operator’s manual for proper use. To help avoid injury: • Always connect return line first and remove last. • Before using system, check that all connections are tight and all lines are undamaged.
  • Page 70 100XT Operator’s Manual Stow Components Stow Components 1. Install all covers. 2. Load components onto trailer. 3. Secure all components on trailer. Restore Jobsite Fill in installation, bursting and service connection pits. Stow Tools Make sure all accessories and tools are loaded and properly secured on trailer.
  • Page 71 100XT Operator’s Manual Stow Tools 70 - Complete the Job...

  • Page 72: Service

    100XT Operator’s Manual Service Chapter Contents Service Precautions ......72 • Remove/Install Front Panel........72 Recommended Lubricants/Service Key .

  • Page 73: Service Precautions

    100XT Operator’s Manual Service Precautions Service Precautions Misuse of machine can cause death or serious injury. Read and understand operator’s manual and all other safety instructions before use. 273-475 To help avoid injury: • Unless otherwise instructed, all service should be performed with engine off.

  • Page 74: Recommended Lubricants/Service Key

    In extreme conditions, service machine more frequently. Use only recommended lubricants. NOTICE: • Use only genuine HammerHead parts and approved lubricants to maintain warranty. • Use the “Service Record” on page 89 to record all required service to your machine. Service - 73...

  • Page 75: Each Use

    100XT Operator’s Manual Each Use Each Use Tasks Notes Inspect rods/pipes after each use Clean jaw after each use Clean rod wipers after each use Inspect Rods/Pipes Inspect rods/pipes after each use. Ensure rods/pipes are not: • severely bent •...
  • Page 76 100XT Operator’s Manual Each Use Clean Rod Wiper IMPORTANT: Replace rod wiper if damaged or worn. Clean rod wiper with high-pressure water after each use. j51om004w19.eps Service - 75...

  • Page 77: 50 Hour

    100XT Operator’s Manual 50 Hour 50 Hour Task Notes Check hydraulic hoses Change hydraulic pressure filter initial change Check Hydraulic Hoses Pressurized fluid or air could pierce skin and cause severe injury. Refer to operator’s manual for proper use. To help avoid injury: •...
  • Page 78 100XT Operator’s Manual 50 Hour Change Hydraulic Pressure Filter (initial) Change hydraulic pressure filter after 50 hours initially, and every 200 hours thereafter. j51om001w.eps Service - 77...

  • Page 79: Hour

    100XT Operator’s Manual 200 Hour 200 Hour Task Notes Change hydraulic pressure filter Change Hydraulic Pressure Filter Change hydraulic pressure filter every 200 hours. j51om001w.eps 78 - Service...

  • Page 80: As Needed

    100XT Operator’s Manual As Needed As Needed Task Notes Replace jaws carriage and bungee Replace spinner and carriage guides Replace rod wiper Replace carriage wheels Lube rod/pipe threads Lube bowls bungee vise and carriage vise, EPRG Replace Jaws Bungee 1. Lift off front of machine. See “Remove/Install Front Panel”...
  • Page 81 100XT Operator’s Manual As Needed Replace Rod Catcher 1. Remove bolts holding plastic guides in place. 2. Remove worn guides. 3. Reinstall new guides using existing hardware. j51om005w.eps Replace Rod Wiper IMPORTANT: Install rod wiper with X facing outward and at top center.
  • Page 82 100XT Operator’s Manual As Needed Lube Bowls Lube bowls as needed. Bungee Vise 1. Move carriage to rear of machine. 2. Through access holes in bungee plate (shown), apply five pumps of EPRG to each grease zerk on each slip.
  • Page 83 100XT Operator’s Manual As Needed 82 - Service...

  • Page 84: Specifications

    100XT Operator’s Manual Specifications Bursting Unit Dimensions U.S. Metric L, length 83 in 2.1 m W, width 30 in 762 mm H, height 39 in 990 mm H2, rod height 18 in 457 mm Weight, mass 3200 lb 1452 kg Operational U.S.
  • Page 85 100XT Operator’s Manual Extraction Cage Extraction Cage Dimensions U.S. Metric L, length 73.5 in 1.9 m W, width 34 in 864 mm H, height 34 in 864 mm Weight, mass 1045 lb 474 kg 84 - Specifications...
  • Page 86 100XT Operator’s Manual Declaration of Conformity Information Declaration of Conformity Information Countries in the European Union should have received a Declaration of Conformity (DOC) with this machine similar to the example below. Earth Tool Company, LLC. 500 South C.P. Avenue...
  • Page 87 100XT Operator’s Manual Declaration of Conformity Information 86 - Specifications...

  • Page 88: Support

    Return damaged parts to dealer for inspection and warranty consideration if in warranty time frame. Order genuine HammerHead replacement or repair parts from your authorized HammerHead dealer. Use of another manufacturer's parts may void warranty consideration.
  • Page 89 Dealer shall furnish parts without charge for any HammerHead product that fails because of defects in material and workmanship. Warranty is void unless warranty registration card is returned within ten days from the date of purchase. This warranty and any...
  • Page 90 100XT Operator’s Manual Service Record Service Performed Date Hours Service Record - 89...
  • Page 91 100XT Operator’s Manual Service Performed Date Hours 90 - Service Record...

Table of Contents